Hockey-Stick Blade with Tailored Performance Regions

ABSTRACT

A hockey-stick blade includes a heel region, a toe region spaced longitudinally from the heel region, and a mid-region located between the heel region and the toe region. The toe region includes one or more reinforcing elements, optionally of different lengths, located at different vertical positions within the toe region. The blade further includes a hosel that optionally is tailored to substantially match the strength and stiffness characteristics of an attached or integral hockey stick shaft. The mid-region of the blade exhibits improved feel and flexibility characteristics due to the increased stiffness in the toe region.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent Ser. No. 16/504,767, filed Jul. 8, 2019, which is a continuation of U.S. patent application Ser. No. 15/869,412, filed Jan. 12, 2018, now U.S. Pat. No. 10,350,470, which is a continuation of U.S. patent application Ser. No. 14/720,639, filed May 22, 2015, now U.S. Pat. No. 9,868,038, which is a continuation of U.S. patent application Ser. No. 13/688,061, filed Nov. 28, 2012 and now U.S. Pat. No. 9,039,549, both of which are incorporated fully herein by reference.

BACKGROUND

Composite hockey-stick blades typically are constructed by wrapping fiber-reinforced plies over one or more elements to create a hockey-stick blade preform. The blade pre-form is then placed within an external mold where resin, which is either pre-impregnated in the fiber plies or added via a resin-transfer process, is cured. An expansion bladder within the blade pre-form, or one or more heat-expanding core elements, may be used to provide internal pressure to mold the blade into the shape of the external mold. The curing process hardens the resin so that the fibers become disposed within a hardened resin matrix, while the mold defines the exterior shape of the cured blade (which sometimes is integrally molded with a hockey-stick shaft).

The fibers in composite hockey-stick blades typically are oriented uniformly throughout the blade, which generally has a substantially uniform thickness. Some blades include separate elements that increase the weight in the heel region or other portions of the blade to provide varied feel and control. The toe region of these blades, however, has been ignored with respect to modifying weight and feel. Further, while isolated regions in some composite blades have been modified, the blades are not tailored throughout their lengths to provide tuned performance and feel throughout the lengths of the blades.

SUMMARY

A hockey-stick blade includes a heel region, a toe region spaced longitudinally from the heel region, and a mid-region located between the heel region and the toe region. The toe region includes one or more reinforcing elements, optionally of different lengths, located at different vertical positions within the toe region. The blade further includes a hosel that optionally is tailored to substantially match the strength and stiffness characteristics of an attached or integral hockey stick shaft. The mid-region of the blade exhibits improved feel and flexibility characteristics due to the increased stiffness in the toe region. Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the same element throughout the various views:

FIG. 1 is a perspective view of a hockey stick according to one embodiment.

FIG. 2 is a partial-perspective view of a hockey-stick blade with the external plies omitted to highlight internal features of the blade.

FIG. 3 is a sectional view of Section 3-3 of FIG. 2.

FIG. 4 is a partial-perspective view of a hockey-stick blade with the face plies omitted to illustrate a serrated reinforcing ply in the toe region of the blade.

DETAILED DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments.

The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.

Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of items in the list.

Turning now in detail to the drawings, as shown in FIGS. 1-3, a hockey stick 10 includes a blade 12 and a shaft 14. The blade 12 may be detachable from the shaft 14 at its upper end, or it may be permanently or integrally attached to the shaft 14. The joint between the blade 12 and the shaft 14 may be formed by a hosel 16 or tenon at the upper-end of the blade 12 that is received within a socket in the lower end of the shaft 14. Any other suitable connections between the blade 12 and the shaft 14, including those disclosed in U.S. Pat. Nos. 7,097,577 and 7,144,343, for example, which are incorporated herein by reference, may be used. The blade 12 and shaft 14 may be constructed in any suitable manner, using any suitable materials, such as by those methods and materials described in incorporated U.S. Pat. Nos. 7,097,577 and 7,144,343, while further incorporating one or more of the additional features described herein.

The blade 12 generally includes the upwardly extending hosel 16 and three regions arranged in a longitudinal direction along the length of the blade: a heel region 20, a toe region 22, and a mid-region 24 located between the heel region 20 and the toe region 22. As described in detail below, each of these regions may be tailored to provide enhanced performance and feel characteristics throughout the blade.

The blade 12 includes a front face (not visible in the figures) and a rear face 28 separated in a lateral direction by a cavity. The cavity is filled with one or more core elements made of foam, elastomeric materials, or one or more other suitable materials, such as those described in incorporated U.S. Pat. Nos. 7,097,577 and 7,144,343. The core elements are wrapped in one or more fiber reinforced plies, such as plies reinforced with carbon, aramid, boron, glass, or other suitable materials, such as those described in incorporated U.S. Pat. Nos. 7,097,577 and 7,144,343.

As shown in FIG. 2, in the illustrated embodiment, the interior of the blade 12 includes four core elements 30, 32, 34, 36 generally running from the toe region 22 to the heel region 20 of the blade 12. The core elements optionally are separated from one another by three structural ribs 40, 42, 44 that also generally run from the toe to the heel of the blade 12. The ribs 40, 42, 44, which provide stiffness and structural support to the blade 12, optionally are made of fiber-reinforced materials that are integral with, adhered to, or otherwise affixed to the front face and the rear face 28 of the blade. Any other suitable number of core elements and ribs may alternatively be used. In other embodiments, a single core element may be used, such that no ribs are included. In still other embodiments, multiple core elements may be used without the inclusion of ribs, such that the core elements abut one another or are spaced apart from one another.

In one embodiment, four core elements 30, 32, 34, 36 are each wrapped in a first ply including carbon fibers oriented at approximately 30° relative to the lateral direction between the front and rear blade faces, and a second ply including carbon fibers oriented at approximately −30° relative to this lateral direction. The two plies optionally may be combined into a single “sandwich ply,” in which the first ply is ironed to-or otherwise attached to or merged with-the second ply. A greater or lesser number of plies may be wrapped around each of the core elements 30, 32, 34, 36, depending on the thickness of the core elements, the thickness of the plies, or the stiffness and flexibility goals of a given blade design.

The hosel 16 optionally extends a significant distance from the heel region 20—and may even have a greater length than that of the blade 12 from the toe region 22 to the heel region 20—as shown in FIG. 1. Further, the hosel 16 preferably includes fibers oriented to approximate the stiffness and strength characteristics of the shaft 14, such that the hosel 16 essentially is a structural extension of the shaft 14. In one embodiment, the hosel 16 includes at least one first ply including fibers oriented at approximately 90° relative to the lateral direction, and at least one neighboring second ply including fibers oriented at approximately 0° relative to the lateral direction, which allows the hosel 16 to “blend in” with most composite hockey-stick shafts, which typically have similar fiber orientations. This blending creates a low “kick point” in the stick 10, which is desirable to many players. As with the plies wrapped around the core elements 30, 32, 34, 36, the plies in the hosel 16 optionally may be combined into one or more sandwich plies.

In one embodiment, the toe region 22 includes one or more reinforcing elements that enhance torque control and blade-tip “preloading” when striking a puck, ball, or other object (collectively referred to herein, for ease of description, as a “puck”). In this manner, the reinforcing elements reduce “lag” of the toe region 22, particularly during a “wrist shot.” The reinforcing elements may include fiber reinforced plies, similar to those used to wrap the core elements 30, 32, 34, 36, or may include other materials that stiffen the blade 12 in the toe region 22. For example, each reinforcing element may be a sandwich ply including “fibers oriented at 30° and −30°, or at 45° and −45°, relative to the lateral direction, or including fibers oriented at any other suitable angles.

These reinforcing plies may be positioned on, adhered to, or wrapped around the plies that are wrapped around the core elements 30, 32, 34, 36. In an alternative embodiment, the reinforcing elements may be directly positioned on, adhered to, or wrapped around the core elements 30, 32, 34, 36 before the plies extending from the toe region 22 to the heel region 20 are wrapped around the core elements, such that the reinforcing elements are contained within these plies. Thus, the reinforcing elements may be indirectly or directly positioned on, adhered to, or wrapped around the core elements.

In the illustrated embodiment, a first reinforcing element 50 is wrapped around the lower edge of the upper core element 30. A second reinforcing element 52 is wrapped around the upper edge of the next core element 32, while a third reinforcing element 54 is wrapped around the lower edge of that core element 32. A fourth reinforcing element 56 is wrapped around the upper edge of the next core element 34, while a fifth reinforcing element 58 is wrapped around the lower edge of that core element 34. Finally, a sixth reinforcing element 60 is wrapped around the upper edge of the lower core element 36.

A greater or lesser number of reinforcing elements may alternatively be included. For example, the two upper reinforcing elements 50, 52 may be omitted, such that four reinforcing elements 54, 56, 58, 60 are used. Further, the number of core elements could be varied such that a greater or lesser number of core-element surfaces, onto which reinforcing elements could be applied, would be exposed. Also, reinforcing elements could be omitted from certain vertical positions to provide varied feel and performance.

In the illustrated embodiment, the first and second reinforcing elements 50, 52 have substantially the same first length; the third and fourth reinforcing elements 54, 56 have substantially the same second length, which is longer than the first length; and the fifth and sixth reinforcing elements 58, 60 have substantially the same third length, which is longer than the second length. Arranging the reinforcing elements in this manner provides increasing stiffness in the toe region 22 as the lower edge of the blade 12 is approached, which generally provides better performance and allows for better puck control. Each of the reinforcing elements alternatively could have substantially the same length, or their lengths could increase as the upper edge of the blade is approached. The individual reinforcing elements may be wrapped only around the lower or upper region of a given core element, or they may be wrapped around an entire core element. In another embodiment, the reinforcing elements may additionally or alternatively be located on the ribs between the core elements.

In one embodiment, the first length of reinforcing elements 50, 52 is approximately 1.0 inch, while the second length of reinforcing elements 54, 56 is approximately 2.5 inches, and the third length of reinforcing elements 58, 60 is approximately 4.0 inches. These reinforcing-element lengths have been found to produce desirable performance and control in the toe region 22, and also to provide better feel and control in the mid-region 24, due to the increased stiffness in the toe region 22 which results in a feeling of increased flexibility in the mid-region 24. Any other suitable reinforcing-element lengths may be used, however, to meet the desired performance and feel characteristics of a given player.

The fiber-angles in any of the blade regions described above may be varied based on desired performance and feel characteristics. For example, on the core elements 30, 32, 34, 36, a first ply including carbon fibers oriented at approximately 45″ relative to the lateral direction may be used in combination with a second ply including carbon fibers oriented at approximately −45°, O′°, or 90° relative to the lateral direction. Similar fiber angles could be used in the plies of the reinforcing elements, as well. Any other suitable combination of fiber angles may alternatively be used.

Once the core elements are wrapped in fiber-reinforced plies, and then reinforcing elements are positioned in the toe region 22, one or more face plies may be wrapped around or otherwise applied to the front and rear surfaces of the wrapped core elements to form a blade pre-form structure. The blade pre-form structure may include additional layers of material, such as one or more glass reinforced, serrated plies 70 positioned around the toe region 22 to increase durability (as shown in FIG. 4), one or more layers of scrim cloth to reinforce the various plies, and any other suitable materials. Once the blade pre-form structure is completed, the blade may be cured using a bladder-molding process, a compression-molding process, or in any other suitable manner, such as by those methods described, for example, in incorporated U.S. Pat. Nos. 7,097,577 and 7,144,343.

The hockey-stick blade 12 described herein provides several advantages. For example, by tailoring the hosel 16 to approximate the stiffness and strength of the shaft 14, the hosel 16 essentially becomes an extension of the shaft and allows for a lower “kick point,” which is preferred by many players. By selectively stiffening portions of the toe region 22, pre-loading and torque control of the toe region 22 are enhanced, and lag is reduced, resulting in greater velocity and accuracy when shooting a puck, particularly during “wrist shots.” Further, by stiffening the toe region, the mid-region, by comparison, exhibits a more flexible feel, allowing for better control of the puck on hard passes and shots.

Any of the above-described embodiments may be used alone or in combination with one another. Further, the hockey stick or hockey-stick blade may include additional features not described herein. While several embodiments have been shown and described, various changes and substitutions may of course be made, without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except by the following claims and their equivalents. 

What is claimed is:
 1. A method of forming a hockey-stick blade comprising: providing a separate upper core element, a separate middle core element, and a separate lower core element; proving the upper core element with an upper core lower edge and wrapping the upper core element lower edge with a first reinforcing element; providing the middle core element with a middle core element upper edge and a middle core element lower edge and wrapping the middle core element upper edge with a second reinforcing element and wrapping the middle core element lower edge with a third reinforcing element; providing the lower core element having a lower core upper edge and wrapping the lower core element upper edge with a fourth reinforcing element; and providing a front face and a rear face.
 2. The method of claim 1 further comprising placing a first rib between the first reinforcing element and the second reinforcing element.
 3. The method of claim 2 further comprising placing a second rib between the third reinforcing element and the forth reinforcing element.
 4. The method of claim 3 wherein the first rib separates the upper core element from the middle core element and the second rib separates the middle core element from the lower core element.
 5. The method of claim 4 further comprising separating the upper core element from the middle core element entirely by the first rib and separating the middle core element from the lower core element entirely by the second rib.
 6. The method of claim 1 further comprising spacing the upper core element, the middle core element and the lower core element apart from one another in a vertical direction from a heel region to a toe region.
 7. The method of claim 1, wherein the first, second, third and fourth reinforcing elements comprise fiber-reinforced plies.
 8. The method of claim 1 further comprising providing one reinforcing element with a length in the longitudinal direction that is greater than a length of another reinforcing element in the longitudinal direction.
 9. A method of forming a hockey-stick blade comprising: providing a separate first core element, a separate second core element, wherein the first core element defines a first core upper edge, a first core first face, a first core second face, and a first core lower edge, wherein the second core element defines second core upper edge, a second core first face, a second core second face, and a second core lower edge; wrapping only the first core element lower edge, the first core first face, the first core second face with a first reinforcing element; wrapping only the second core element upper edge, the second core first face, and the second core second face with a second reinforcing element; placing the first core element and the second core element adjacent to one another; and providing a front face and a rear face.
 10. The method of claim 9, further comprising placing a rib between the first reinforcing element and the second reinforcing element.
 11. The method of claim 11, wherein the rib separates the first core element from the second core element.
 12. The method of claim 12, further comprising separating the first core element from the second core element entirely by the rib.
 13. The method of claim 9 further comprising spacing the first core element and the second core element apart from one another in a vertical direction from a heel region to a toe region.
 14. The method of claim 9, wherein the first and second reinforcing elements comprise fiber-reinforced plies and the first rib is formed of fiber-reinforced materials.
 15. The method of claim 9 further comprising providing one reinforcing element with a length in the longitudinal direction that is greater than a length of another reinforcing element in the longitudinal direction.
 16. A method of forming a hockey-stick blade comprising: providing a separate upper core element, a separate middle core element, and a separate lower core element, wherein the upper core element defines an upper core upper edge, an upper core first face, an upper core second face, and an upper core lower edge, wherein the middle core element defines a middle core upper edge, a middle core first face, a middle core second face, and a middle core lower edge, wherein the lower core element defines a lower core upper edge, a lower core first face, a lower core second face, and a lower core lower edge; wrapping only the upper core element lower edge, the upper core first face, the upper core second face with a first reinforcing element; wrapping only the middle core element upper edge, the middle core first face, and the middle core second face with a second reinforcing element and wrapping only the middle core element lower edge, the middle core first face, and the middle core second face with a third reinforcing element; wrapping only the lower core element upper edge, the lower core first face, and the lower core second face with a fourth reinforcing element placing a first rib between the first reinforcing element and the second reinforcing element; placing a second rib between the third reinforcing element and the forth reinforcing element.
 17. The method of claim 16, wherein the first rib separates the upper core element from the middle core element and the second rib separates the middle core element from the lower core element.
 18. The method of claim 16 further comprising spacing the upper core element, the middle core element and the lower core element apart from one another in a vertical direction from a heel region to a toe region.
 19. The method of claim 16, wherein the first, second, third and fourth reinforcing elements comprise fiber-reinforced plies and the first and second ribs are formed of fiber-reinforced materials.
 20. The method of claim 16 wherein the first, second, and third cores comprise foam. 